Stamping die

ABSTRACT

A forming system includes a first die assembly having a first die surface, a second die assembly having a second die surface; a movable die block having a third die surface; and a cooling system. The first die surface, the second die surface and the third die surface are configured to cooperate to form a die cavity therebetween so as to receive a work piece therein. A relative movement between the first die assembly and the second die assembly along a first axis moves the die cavity between an open position and a closed position. The die block is movable relative to the first die assembly in a direction transverse to the first axis and applies a force to the work piece that is predominantly transverse to forces applied to the work piece by the first die assembly and the second die assembly.

This application claims the priority to U.S. Patent Application No.62/198,980, filed Jul. 30, 2015, which is hereby incorporated byreference in its entirety.

FIELD

The present patent application relates to a system and method forforming a sheet metal member.

BACKGROUND

Vehicle manufacturers strive to provide vehicles that are increasinglystronger, lighter and less expensive. One proposed solution includes theuse of heat-treated sheet steel panel members to form the vehicle bodypanel members. In some applications, the sheet steel panel members areformed in a forming process and subsequently undergo a heat-treatingoperation. This two-stage processing may be disadvantageous in that theadditional operation may add significant cost and time.

As an alternative to a process that employs a discrete heat-treatingoperation, it is known that certain materials, such as boron steels, maybe formed and quenched in a hot forming die system. In this regard, apre-heated sheet stock may be typically introduced into a hot formingdie system, formed to a desired shape and quenched subsequent to theforming operation while in the die system to thereby produce a heattreated component. The known hot forming dies for performing the hotforming and quenching steps typically employ water cooling passages (forcirculating cooling water through the hot forming die system) that areformed in a conventional manner.

For example, formed components or parts can be quenched during theforming stage/procedure to ensure transformation from Austenite toMartensite. Cooling should be performed relatively quickly to allow forsuch transformation to occur and to reduce cycle time. There may be apoor contact/pressure on sidewall(s) of the formed component thatresults in a low coefficient of heat transfer and thus cooling rates maynot be fast enough to reach Martensite. This may cause certain areas ofthe formed component to not meet desired mechanical properties.Alternately, even if the quenching time is sufficient to reachMartensite, there is still a desire to cool even more quickly to reducecycle time of the cooling (and hence entire forming) operation.

The present patent application provides improvements to the hot formingsystems and hot forming operations.

SUMMARY

One aspect of the present patent application provides a forming systemthat includes a first die assembly having a first die surface, a seconddie assembly having a second die surface, a movable die block having athird die surface, and a cooling system operatively associated with thefirst die assembly, the second die assembly and the movable die block.The first die surface, the second die surface and the third die surfaceare configured to cooperate to form a die cavity therebetween so as toreceive a work piece therein. Relative movement between the first dieassembly and the second die assembly along a first axis moves the diecavity between an open position and a closed position. The die block ismovable relative to the first die assembly in a direction transverse tothe first axis, and the die block applies a force to the work piece thatis predominantly transverse to forces applied to the work piece by thefirst die assembly and the second die assembly.

Another aspect of the present patent application provides a method offorming a sheet metal member in a forming system is provided. Theforming system includes a first die assembly having a first die surface,a second die assembly having a second die surface, a movable die blockhaving a third die surface, and a cooling system operatively associatedwith the first die assembly, the second die assembly and the movable dieblock. The first die surface, the second die surface and the third diesurface are configured to cooperate to form a die cavity therebetween soas to receive a work piece therein. The method includes moving the firstdie assembly relative to the second die assembly along a first axis tomove the die cavity from an open position to a closed position, movingthe die block relative to the first die assembly in a directiontransverse to the first axis, and applying a force to the work piecewith the die block that is predominantly transverse to forces applied tothe work piece by the first die assembly and the second die assembly.

While the present disclosure can be used for forming automobile bodypanels, the same system and method can be used to form sheet steel thatcan be used for other applications.

These and other aspects of the present patent application, as well asthe methods of operation and functions of the related elements ofstructure and the combination of parts and economies of manufacture,will become more apparent upon consideration of the followingdescription and the appended claims with reference to the accompanyingdrawings, all of which form a part of this specification, wherein likereference numerals designate corresponding parts in the various figures.In one embodiment of the present patent application, the structuralcomponents illustrated herein are drawn to scale. It is to be expresslyunderstood, however, that the drawings are for the purpose ofillustration and description only and are not intended as a definitionof the limits of the present patent application. It shall also beappreciated that the features of one embodiment disclosed herein can beused in other embodiments disclosed herein. As used in the specificationand in the claims, the singular form of “a”, “an”, and “the” includeplural referents unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of a hot stamping/forming system inaccordance with an embodiment of the present patent application;

FIG. 1A is a flow diagram of a method for forming a body member usingthe forming system in accordance with an embodiment of the presentpatent application;

FIGS. 2 and 3 are schematic diagrams of a hot stamping/forming system inaccordance with another embodiment of the present patent application;

FIGS. 4 and 5 are schematic diagrams of a hot stamping/forming system inaccordance with yet another embodiment of the present patentapplication; and

FIG. 6 shows a sectional view of an upper die assembly of the hotstamping/forming system shown in FIGS. 4 and 5.

DETAILED DESCRIPTION

FIG. 1 shows a forming system 10 for producing a sheet metal part, suchas a vehicle body member or panel. The forming system 10 may be a hotforming system or a stamping die system. Referring to FIG. 1, theforming system 10 includes a first die assembly 12, a second dieassembly 14, a movable die block 16 and a cooling system 18 operativelyassociated with the first die assembly 12, the second die assembly 14,and the movable die block 16.

In illustrative embodiment, the first die assembly 12 is shown as anupper die assembly. In another embodiment, the first die assembly 12 maybe a lower die assembly. The first die assembly 12 includes a first dieshoe or die holder 20, a first die body 22, and a first die surface 24.The upper die assembly 12 may be mounted in a stamping press or ram (notshown) to enable upwards and downwards movement of the upper dieassembly 12. The stamping press or press ram may be driven hydraulicallyor mechanically (e.g., by an electric motor).

In one embodiment, the first die shoe or die holder 20 may be a supportmember, block or plate of the forming system 10 that secures a punchretainer (not shown), which is a device used to mount the first die bodyor punch 22 on the first die shoe or die holder 20. In one embodiment,the punch retainer is optional and the first die body or punch 22 isdirectly mounted on the first die shoe or die holder 20. In oneembodiment, the first die shoe or die holder 20 may be made of a metalmaterial.

In one embodiment, the first die body 22 may be referred to as a punch.In one embodiment, the first die body 22 may be formed of a heatconducting material such as tool steel, in particular DIEVAR®, which ismarketed by Bohler-Uddeholm Corporation of Rolling Meadows, Ill., orcommercially available H-11 or H-13. In one embodiment, the first diebody 22 may also include a plurality of cooling structures or channels26 in at least a portion thereof. In one embodiment, the first diesurface 24 may include a complex forming die surface.

In illustrative embodiment, the second die assembly 14 is shown as alower die assembly. In another embodiment, the second die assembly 14may be an upper die assembly. In one embodiment, the second die assembly14 includes a second die shoe or die holder 28, a second die body 30,and a second die surface 32.

In one embodiment, the second die shoe or die holder 28 may be a supportmember, block or plate of the forming system 10 that secures a dieretainer (not shown), which is a device used to mount the second diebody or die 30 on the second die shoe or die holder 28. In oneembodiment, the die retainer is optional and the second die body or die30 is directly mounted on the second die shoe or die holder 28. In oneembodiment, the second die shoe or die holder 28 may be made of a metalmaterial.

In one embodiment, the second die body 30 may be referred to as a die.In one embodiment, the second die body 30 may be formed of a heatconducting material such as tool steel, in particular DIEVAR®, which ismarketed by Bohler-Uddeholm Corporation of Rolling Meadows, Ill., orcommercially available H-11 or H-13. In one embodiment, the second diebody 30 may also include a plurality of cooling structures or channels34 in at least a portion thereof. In one embodiment, the second diesurface 32 may include a complex forming die surface.

The movable die block 16 of the forming system 10 includes a third diesurface 36. The first die surface 24 of the first die assembly 12, thesecond die surface 32 of the second die assembly 14 and the third diesurface 36 of the movable die block 16 are configured to cooperate toform a die cavity 38 therebetween so as to receive a work piece 40therein. In one embodiment, the die cavity 38 is configured to have ashape that corresponds to a final shape of the work piece 40 after thehot forming operation/procedure. In the illustrative embodiment shown,the cavity and shape of the part or work piece will have a tophatcross-sectional configuration.

As used herein, the term “die surface” refers to the portion of theexterior surface of a die assembly that forms a hot formed component andcomes in direct contact with the portions of the work piece. Moreover,the term “complex die surface” as used in this description means thatthe die surface has a three-dimensionally contoured shape.

In the illustrative embodiment, the first die surface 24 may begenerally horizontal die surface, while the second die surface 32 andthe third die surface 36 may include a combination of generally verticaldie surfaces and generally horizontal die surfaces. In anotherembodiment, the first die surface 24, the second die surface 32 and thethird die surface 36 may include a combination of generally vertical diesurfaces, generally horizontal die surfaces, generally angular diesurfaces, generally arcuate die surfaces and/or generally other contourshaped die surfaces.

In one embodiment, the work piece 40 may be a sheet metal blank, whichmay be formed of a heat-treatable steel, such as boron steel. In anotherembodiment, the work piece 40 may be stamped from a sheet of hardenablesteel, such as Usibor®1500P or Usibor® 1500, boron steel or any suitablehot stamp press hardened material. In one embodiment, the work piece 40may be pre-shaped specifically for producing a desired shaped hot formedproduct, such as, for example, by an additional cutting procedure or anadditional cold forming procedure. In one embodiment, the additionalcutting procedure or additional cold forming procedure may be optional.In one embodiment, the work piece 40 may be a substantially four-sided,rectangular configuration. It should be appreciated, however, that thepresent application is not limited to sheet metal blanks of suchconfiguration.

Relative movement between the first die assembly 12 and the second dieassembly 14 along a first axis A-A moves the die cavity 38 between anopen position and a closed position. In one embodiment, the first axisA-A may be a longitudinal axis of the forming system 10. In oneembodiment, the upper/first die assembly 12 is movable with respect tothe lower/second die assembly 14 from an open position in which the dieassemblies 12 and 14 are separated from each other to a closed positionin which the die assemblies 12 and 14 form the closed die cavity 38. Inone embodiment, the second die assembly 14 is fixedly mounted in theforming system or the stamping press. In the illustrative embodiment,the first die assembly 12 is movably mounted with respect to the fixedsecond die assembly 14. That is, the first die assembly 12 is configuredto move downwardly along the first axis A-A such that the first die body22 and the movable die block 16 cooperate with the second die assembly14 to form the closed die cavity 38 therebetween. However, it iscontemplated that the relative movement of the die assemblies may beaccomplished through movement of either the upper/first die assembly 12,or the lower/second die assembly 14, or both, with respect to eachother.

In one embodiment, the first die assembly 12 and the second die assembly14 may be mounted in the stamping press. The stamping press may beconfigured to close the first and second die assemblies 12 and 14 in adie action direction (i.e., along or parallel to the first axis A-A) todeform the work piece 40 received in the die cavity 38 so as to form andoptionally trim a hot formed member. In one embodiment, the stampingpress may be configured to maintain the die assemblies 12 and 14 in aclosed relationship for a predetermined amount of time to permit theformed member to be cooled to a desired temperature.

In one embodiment, the movable die block 16 may be referred to as a camslide member. In one embodiment, the movable die block 16 of the formingsystem 10 may be part of the first die assembly 12. In one embodiment,as shown in FIG. 1, the movable die block 16 may include a first movabledie block 16 a and a second movable die block 16 b. The first movabledie block 16 a and second movable die block 16 b are positioned oneither side of the first die body 22. In one embodiment, the firstmovable die block 16 a and second movable die block 16 b are mounted onthe first die shoe or die holder 20 of the first die assembly 12.

In the illustrative embodiment, one movable die block is shown on eachside (i.e., right side and left side) of the forming system 10. However,it is contemplated that the number of movable die blocks on each side(i.e., right side and left side) of the forming system 10 may vary. Forexample, in one embodiment, the forming system may include only one dieblock. In another embodiment, the forming system 10 may include a twomovable die blocks per side configuration, that is, two movable dieblocks 16 on the right side and two movable die blocks 16 on the leftside. In another embodiment, the forming system 10 may include a threemovable die blocks per side configuration with three movable die blocks16 on the right side and three movable die blocks 16 on the left side.In one embodiment, the width of each movable die block in the twomovable die blocks per side configuration is wider than the width ofeach movable die block in the three movable die blocks per sideconfiguration. In one embodiment one or more die blocks can be providedin the lower die structure (which can in such instance be considered thefirst die assembly), rather than the upper die structure.

In one embodiment, as shown in FIG. 1, wear plates or members 42 areprovided at the interface between the movable die block 16 and the fixedupper/first die shoe or die holder 20. In one embodiment, the wearplates or members 42 may be made from hardened steel material. The wearplates or members 42 may be configured to provide guide and wearsurfaces between the movable die block 16 and the fixed upper/first dieshoe or die holder 20. That is, the wear plates or members 42 areconfigured to provide guide and wear surfaces to the movable die block16 as the movable die block 16 moves relative to the first die body 22and the first die assembly 12. In one embodiment, wear plates or members42 a and 42 b are provided at the interface between the fixedupper/first die shoe or die holder 20 and the respective movable dieblock 16 a and 16 b.

In one embodiment, the die block 16 is movable relative to the first dieassembly 12 in a direction transverse to the first axis A-A. In oneembodiment, the die block 16 is movable relative to the first die body22 in a direction transverse to the first axis A-A. In one embodiment,the movement of the die block 16 relative to the first die assembly 12and/or first die body 22 is a linear sliding movement in a directiontransverse to the longitudinal axis A-A. In one embodiment, the dieblock 16 is movable relative to the first die assembly 12 and/or firstdie body 22 in a direction perpendicular to the longitudinal axis A-A ofthe forming system 10.

In the illustrative embodiment, the die cavity 38 is in the closedposition. When the die cavity 38 is in the closed position, the firstand second die surfaces 24 and 32 apply forces F to the work piece 40 ina direction generally corresponding to the first axis A-A. That is, thefirst and second die surfaces 24 and 32 apply the forces F to the workpiece 40 in a direction generally parallel to or along the first axisA-A. In one embodiment, when the die cavity 38 is in the closedposition, portions 36 h of the third die surface 36 and portions 32 h ₁of the second die surface 32 apply the forces F to the work piece 40 ina direction generally corresponding to, along or parallel to the firstaxis A-A. In one embodiment, the portions 36 h of the third die surface36 and the portions 32 h ₁ of the second die surface 32 may be generallyhorizontal die surfaces.

In one embodiment, the die block 16, 16 a, or 16 b applies a force SF tothe work piece 40 that is predominantly transverse to the forces Fapplied to the work piece by the first die assembly 12 and the seconddie assembly 14. In one embodiment, the die block 16 applies the forceSF to the work piece that is perpendicular to the forces F applied tothe work piece 40 by the first die assembly 12 and the second dieassembly 14. In another embodiment, the die block 16 applies the forceSF to the work piece 40 that is angular to the forces F applied to thework piece 40 by the first die assembly 12 and the second die assembly14. In one embodiment, the angle between the force SF applied to thework piece 40 by the die block 16 and the forces F applied to the workpiece 40 by the first die assembly 12 and the second die assembly 14 mayrange between about 30 and 150 degrees. In another embodiment, the anglebetween the force SF applied to the work piece 40 by the die block 16and the forces F applied to the work piece 40 by the first die assembly12 and the second die assembly 14 may range between about 60 about 120degrees.

In one embodiment, the two moveable die structures (i.e., first die body22 and movable die block 16) and the single fixed die structure (i.e.,second die body 30) together define the die cavity 38 of the formingsystem 10. Relative movement between the moveable die structures 22 and16 and the single fixed die structure 30 closes the die cavity 38. Afterthe die cavity 38 is closed, movement of the movable die structure 16relative to the moveable die structure 22 applies a force on the workpiece 40 that is predominantly transverse to forces applied to the workpiece 40 by the first die assembly 12 and the second die assembly 14.This force provides a good contact/pressure on sidewall(s) of the formedcomponent that results in a high coefficient of heat transfer and thuscooling rates that are fast enough to reach Martensite.

The first die assembly 12, the second die assembly 14 and the movabledie block 16 are operatively coupled to the cooling system 18 such thatthe first die assembly 12, the second die assembly 14 and the movabledie block 16 are configured to cool the work piece 40 in contacttherewith when the die cavity 38 is closed. For example, the first diebody 22, the second die body 30 and the movable die block 16 areoperatively coupled to the cooling system 18.

The cooling system 18 may include a source of cooling fluid. In oneembodiment, cooling fluid may include water, oil, saline, gas or otherfluid medium. Cooling fluid, provided by the cooling system 18, may becontinuously circulated through the cooling channels or structures tocool the die assemblies 12 and 14 and the movable die block 16. In oneembodiment, the cooling system 18 may include a reservoir/chiller. Inone embodiment, the cooling system 18 may include a pressure source or afluid pump for forcing the cooling fluid through the cooling channels orstructures. In one embodiment, the cooling fluid may be cycled in acontinuous, uninterrupted manner, but it will be appreciated that theflow of cooling fluid may be controlled in a desired manner to furthercontrol the cooling of the die surfaces. It may be appreciated thatcirculating cooling fluids cools the die assemblies 12 and 14 and themovable die block 16, and that the cooled die assemblies 12 and 14 andthe cooled movable die block 16, in turn, quench and cool the hot formedmember.

In one embodiment, the first die body 22, the second die body 30 and themovable die block 16 may include cooling channels or structures 26, 34and 44, respectively, that are constructed and arranged to carry acooling fluid. In one embodiment, the cooling channels or structures maybe formed by techniques such as gun drilling that yield straightchannels extending through the respective die bodies and/or movable dieblock(s). In one embodiment, the cooling channels or structures areformed by gun drilling the cooling channels through one or two sides ofthe respective die bodies and/or the movable die block(s).

In one embodiment, each cooling channel or structure 26 may be offsetfrom the die surface 24 by a first predetermined distance and thisdistance may be consistent along the length of the cooling channels 26.Similarly, each cooling channel 34 may be offset from the die surface 32by a second predetermined distance, which may be different from thefirst predetermined distance, and this distance may be consistent alongthe length of the cooling channels 34. Similarly, each cooling channel44 may be offset from the die surface 36 by a third predetermineddistance, which may be different from the first predetermined distanceand/or second predetermined distance, and this distance may beconsistent along the length of the cooling channels 44. In anotherembodiment, the first, second and third predetermined distance may bethe same.

The distance between the cooling channels 26, 34, and 44 and theirrespective complex die surfaces 24, 32 and 36 as well as the mass flowrate of the cooling fluid and the temperature of the fluid are selectedto control the cooling of the lower and upper die assemblies 12 and 14and the movable die block 16 such that the hot-stamped component isquenched in a controlled manner consistently across its major surfacesto cause a phase transformation to a desired metallurgical state (i.e.,Martensite). In one embodiment, the blank or work piece 40 is heatedsuch that its structure is substantially (if not entirely) composed ofaustenite, the heated blank/work piece 40 is formed between the lowerand upper die assemblies 12 and 14 and the movable die block 16. Thehot-stamped component is quenched by the lower and upper die assemblies12 and 14 and the movable die block 16 prior to the ejection of thehot-stamped component from the forming system 10. In this regard, thelower and upper die assemblies 12 and 14 and the movable die block 16function as heat sinks to draw heat from and thereby quench thehot-stamped component in a controlled manner to cause a desired phasetransformation (e.g., to Martensite) in the hot-stamped component andoptionally to cool the hot-stamped component to a desired temperature.

In one embodiment, the forming system 10 may include a pair of camdriver members 46 (46 a, 46 b) and a pair of gas cylinder springs 48 (48a, 48 b). In another embodiment, instead of the gas cylinder springs,the forming system may use any other biasing devices or mechanisms. Inone embodiment, the force applied by the gas cylinder springs may bedifferent from the force applied by the stamping press or ram.

In one embodiment, the gas cylinder spring 48 includes a cylinder thatis sealed on both ends. The cylinder also includes a shaft connected toa piston reciprocating within the cylinder and extending out one end ofthe cylinder. In one embodiment, the forming system 10 includes amanifold configured for supplying gas or nitrogen under pressure to thecylinder and a pressure sensor configured to be operatively coupled tothe manifold for providing a pressure signal of gas or nitrogen in themanifold.

The shaft or the piston extension is operatively connected to the camdriver member 46. The gas may be nitrogen or other similar inert gases.The pressure provided by the gas applies force to the piston and causesthe shaft to be extended. In one embodiment, the amount of force appliedby the cylinder may be varied to compensate for any material thicknessdiscrepancies found in the work piece 40. The gas cylinder spring 48 isconfigured to be compressed by the cam driver member 46. The gascylinder spring 48 is also configured to return the cam driver member 46to its original position (inward towards the center of the forming tool)after the cam driver member 46 has been moved away from the center ofthe forming tool during the forming procedure. In one embodiment, thegas cylinder spring 48 may be configured to restrict or control the(horizontal) movement of the cam driver member 46 with respect to themovable die block 16. In one embodiment, the gas cylinder spring 48 maybe configured to help compensate for any material thicknessdiscrepancies found in the work piece 40.

Each cam driver member 46 is movable with respect to the lower dieassembly 14. Each cam driver member 46 is operatively associated with anitrogen cylinder spring 48 and is mounted for horizontal movement withrespect to the lower die assembly 14 by the associated nitrogen cylinderspring. That is, each nitrogen cylinder spring 48 is configured to beexpandable and retractable to affect the movement of the associated camdriver member 46 relative to the second die assembly 14. Each nitrogencylinder spring 48 is configured to affect the movement of theassociated cam driver member 46 towards and away from the first and thesecond die bodies 22 and 30. In one embodiment, the movement of the camdriver member relative to the lower die assembly 14 is a linear slidingmovement in a direction transverse or perpendicular to the longitudinalaxis A-A of the forming system 10.

In one embodiment, the cam driver member 46 includes an upwardly facingslanted cam surface 50 which is constructed and arranged to cooperate orengage with a downwardly facing slanted cam surface 52 of the movabledie block 16.

As shown in FIG. 1, wear plates or members 54 (54 a, 54 b) are providedat the interface between each movable cam driver member 46 and the fixedlower die shoe structure 28. In one embodiment, the wear plates ormembers 54 may be made from hardened steel material. The wear plates ormembers 54 may be configured to provide guide and wear surfaces betweenthe movable cam driver member 46 and the fixed lower/second die shoe ordie holder 28. That is, the wear plates or members 54 are configured toprovide guide and wear surfaces to the movable cam driver member 46 asthe cam driver member 46 moves relative to the fixed lower/second dieshoe or die holder 28.

The operation of the forming system 10 will now be described.

In one embodiment, as shown in FIG. 1A, a method 1000 of forming a sheetmetal member in the forming system 10 is provided. In one embodiment,the sheet metal member may include a vehicle body member or panel. Inone embodiment, the method 1000 may include procedures 1002-1004. Forexample, at procedure 1002, the first die assembly 12 is moved relativeto the second die assembly 14 along a first axis A-A to move the diecavity 38 from an open position to a closed position. At procedure 1004,the die block 16 is moved relative to the first die assembly 12 in adirection transverse to the first axis A-A. At procedure 1006, a forceis applied to the work piece 40 with the die block 16 that ispredominantly transverse to forces applied to the work piece 40 by thefirst die assembly 12 and the second die assembly 14. Each of theseprocedures 1002-1004 and other optional/additional procedures of themethod 1000 will be described in detail below.

When the upper/first die shoe or die holder 20 is withdrawn, by thestamping press or ram, to its highest position, the die cavity is theopen position. In one embodiment, the die cavity is in the openposition, when the upper/first die shoe or die holder 20 is withdrawn toan intermediate position. As the upper/first die body 22 and the movabledie block 16 are operatively coupled to the upper/first die shoe or dieholder 20, the upper/first die body 22 and the movable die block 16 arealso withdrawn to their highest positions along with the upper/first dieshoe or die holder 20. In one embodiment, the upper die assembly 12 ismoved to a die/lowered/closed position, with respect to the lower/seconddie body 30, in order to stamp or form the work piece 40 to a desiredconfiguration. In one embodiment, the upper die assembly 12 is moved toa die/lowered/closed position by the stamping press or ram.

When the die cavity is the open position, the nitrogen cylinder spring48 applies pressure or force on the cam driver member 46 sliding itinwards towards the center of the forming system 10 (and towards thesecond die assembly 14). In one embodiment, the nitrogen cylindersprings 48 a and 48 b are configured to apply pressure to the associatedcam driver members 46 a and 46 b sliding them in the direction of arrowsCDA and CDB, respectively towards the center of the forming system 10.That is, prior to the beginning of the next forming cycle, the gascylinder springs are energized to move the associated cam driver membersto their original positions.

The forming procedure begins with the configuration in which a pre-cutblank sheet of metal material or work piece 40 is placed upon the lowerdie body 30, when the die cavity is the open position. In particular,the underside of the work piece 40 is laid to rest upon an upwardlyfacing, lower clamping surface 32 of the lower die body 30.

In one embodiment, the work piece 40 is heated to an austenitizingtemperature during the hot forming procedure. The work piece 40 (e.g.,stamped or pre-shaped) is heated to the austenite state. For example,the work piece 40 is heated in an oven or a furnace (e.g., aroller-hearth or a batch style) to a temperature above the Ac3temperature. In one embodiment, the work piece 40 may be pre-heated to apredetermined temperature, such as about 930° C. In one embodiment, thework piece 40 may be pre-heated to a predetermined temperature, such asabout 900° C. In one embodiment, the work piece 40 is heated such thatits structure is substantially (if not entirely) composed of austenite.Once the work piece 40 is in the austenite state, the work piece 40 maybe transferred quickly/rapidly to the die assemblies 12 and 14.

After the work piece 40 is mounted on the lower die body 30, the dieassemblies 12 and 14 may then be brought together (i.e., closed) in thedie action direction via the stamping press or ram to cause the hotformed member to be formed. For example, the upper die shoe 20 islowered (to its die position) by the stamping press or ram until adownwardly facing, lower clamping surface 24 of the upper die body 22engages the upwardly facing surface of the sheet metal blank 40 and/or adownwardly facing, lower clamping surface 36 h or 36 of the movable dieblock 16 engages the upwardly facing surface of the sheet metal blank 40such that the work piece 40 is sandwiched between the die surface 24 ofthe upper die body 22, the die surface 36 of the movable die block 16and the die surface 32 of the lower die body 30.

The lowering of upper die shoe 20 effects lowering of the upper die body22 and the movable die block 16. In one embodiment, the movement of themovable die block 16 is a linear longitudinal downwardly movement. Inone embodiment, the movement of the movable die block 16 is a verticalmovement. In one embodiment, the movement of the movable die block 16 isin the direction of an arrow DF. As the upper die assembly 12 is loweredfrom its highest or intermediate position to its die position, thedownwardly facing slanted cam surface 52 of the movable die block 16engages or contacts the upwardly facing slanted cam surface 50 of thecam driver member 46. That is, as the movable die block 16 moves in thedownwardly direction, the upwardly facing slanted cam surface 50 of thecam driver member 46 slidingly engages and bears against the downwardlyfacing slanted cam surface 52 of the movable die block 16 therebyadvancing the movable die block 16 in a direction transverse to theaxial downwardly direction of the movement of the movable die block 16.In one embodiment, the movement of the movable die block portion 16 is atransverse or lateral movement (towards the center of the forming system10). In another embodiment, the movement of the movable die block 16 isa linear transverse or lateral movement (towards the center of theforming system 10). In one embodiment, the movement of the movable dieblock portion 16 is in the direction of an arrow S,

The engagement of the downwardly facing slanted cam surface 52 and theupwardly facing slanted cam surface 50 causes a camming effect on themovable die block 16 to drive the movable die block 16 against the lowerdie body 30. The inwardly transverse movement of the movable die block16 exerts a force on the work piece 40 received in the die cavity 38. Inone embodiment, the movable die block 16 is configured to apply pressureto the side walls of the work piece 40 received in the die cavity 38 (orthe formed part).

Thus, the downward axial force of the movable die block 16 is translatedinto a side or laterally applied force on the work piece 140 by the dieblock 16. The arrangement of the cam driver member and the movable dieblock 16 are configured to convert the axial or longitudinal movement ofthe movable die block 16 into a lateral or transverse movement oftranslation (of the movable die block 16) so as to apply a transverseforce on the work piece 40 received in the die cavity 38. In oneembodiment, the force may be translated from downward (of the movabledie block 16) to side or lateral (on the side walls of the work piece140) by about 90 degree. In another embodiment, the force may betranslated from downwards to side or lateral by about 30 to 150 degree.In another embodiment, the force may be translated from downwards toside or lateral by about 60 to 120 degree.

The cam driver member 46 is configured to force the movable die block 16against the lower die body 30 creating pressure against the work piece40. Urging the die surface 36 of the movable die block 16 tightlyagainst its adjoining contact surface of the work piece 40 increases thearea of contact between the movable die block 16 and the work piece 40,and provides an improved heat transfer path between the work piece 40and the movable die block 16.

For example, the movable die block 16 is configured to movable relativeto the first die assembly 12 (including the upper/first die show orholder 20 and the upper/first die body 22) to apply or exert a contactpressure force on portions of the work piece 40 that are in directcontact with the third die surface 36 of the movable die block 16 so asto increase thermal conductivity or heat transfer from the work piece 40to the movable die block 16. The forming system 10 may be configured toprovide good contact between the die surface 36 of the movable die block16 and its adjoining contact surface of the work piece 40 so as toachieve uniform, contact pressure across the work piece 40. The cammingaction has effected displacement of the movable die block 16 so as toimpose maximum contact pressure between the work piece 40 and themovable die block 16. In one embodiment, the movable die block 16 isconfigured to apply the contact pressure force on the side walls of theformed component at the bottom of the press ram's downward stroke. Thatis, the movable die block 16 is configured to contact the side walls ofthe formed component under pressure at the bottom of the downwardstroke. In one embodiment, increased force applied by the third diesurface 36 against the work piece 40 increases thermal transfer betweenthe third die surface 36 and the work piece 40.

As the die assemblies 12 and 14 close (i.e., the first die body 22 andthe movable die block 16 cooperate with the second die assembly 14 toform the closed die cavity 38 therebetween), the movable die block 16 isconfigured to apply pressure through the cam driver member 46 andcompress the nitrogen cylinder 48.

Thus, the forming system 10 on the die close applies a pressure on theside walls or portions of the work piece 40 that are in direct contactwith the movable die block 16. The pressure is applied via the gascylinder springs 48 to the cam driver members 46 in turn pushing ontothe movable die blocks 16. The movable die blocks 16 apply pressure tothe side walls of the formed part. This provides sufficient contactpressure to achieve an acceptable heat transfer coefficient in turnallowing the entire part to transform into Martensite.

In one embodiment, the amount of travel of the movable die block may bein the range of about 0.2 to 0.5 mm. In one embodiment, the amount oftravel of the movable die block 16 may be determined by the distancebetween upper and lower radius tangent.

In one embodiment, the formed component is hardened by cooling theportions thereof at a rate of cooling that is sufficiently rapid/fast toform a Martensitic structure in the formed component. Deformation andconcomitant rapid cooling of the portions of the formed component withinthe die assemblies 12 and 14 produces the hot formed component, in whichthe austenite structure has been transformed into the Martensiticstructure. For example, in one embodiment, the cooling rate of theformed component may be in the range of about 30° C./second to about100° C./second. In one embodiment, the formed component in directioncontact with the die surfaces is cooled from about 900° C. to 200° C. inabout 7 to 8 seconds. In one embodiment, the cycle time for the hotformed member is about 7 to 8 seconds. In one embodiment, the hot formedmember may be cooled by the die assemblies 12 and 14 prior to theejection of the hot formed member from the die assemblies 12 and 14.

After the quenching procedure, the die assemblies 12 and 14 may beseparated from one another (i.e., opened). That is, the stamping pressthen passes through its bottom dead center and returns on its upwardstroke. The hot formed component may be removed from the die cavity 38.For example, the formed component is then pushed upwards from the bottomdie assembly 14 and an operator or a robot then removes the finishedcomponent from the forming system 10 while it is in a relaxed state. Inone embodiment, after being removed from the die assemblies 12 and 14,the member may be cooled to about room temperature, or at least to atemperature between about 20° C. and about 250° C. In one embodiment,additional processing procedure(s) may be performed. These additionalprocessing procedure(s) may include trimming, perforating, etc.

FIGS. 2 and 3 are schematic diagrams of a hot stamping/forming system110 in accordance with another embodiment of the present patentapplication. The hot stamping/forming 110 includes a first die assembly112 having a first die surface 124, a second die assembly 114 having asecond die surface 132, and a movable die block 116 having a third diesurface 136. The first die surface 124, the second die surface 132 andthe third die surface 136 are configured to cooperate to form a diecavity 138 therebetween so as to receive a work piece 140 therein.Relative movement between the first die assembly 112 and the second dieassembly 114 along a first axis A′-A′ moves the die cavity 138 betweenan open position and a closed position. The die block 116 is movablerelative to the first die assembly 112 in a direction transverse to thefirst axis A′-A′, and the die block applies a force SF′ on the workpiece 40 that is predominantly transverse to forces F′ applied to thework piece 140 by the first die assembly 112 and the second die assembly114.

The system 110 also includes a cooling system 118 operatively associatedwith the first die assembly 112, the second die assembly 114 and themovable die block 116. In one embodiment, elements of the cooling system118 may generally resemble and function in a manner similar tocorresponding elements of the cooling system 18. Although notillustrated, the first die assembly 112, the second die assembly 114 andthe movable die block 116 each include a cooling structure associatedtherewith so that the first die surface, the second die surface and thethird die surface cool the work piece 140 in contact therewith when thedie cavity 138 is closed.

This embodiment is similar to the embodiment previously described,except for the differences as will be noted below.

In one embodiment, the movable die block 116 includes a first movabledie block portion 116 a and a second movable die block portion 116 b.The first movable die block portion 116 a and the second movable dieblock portion 116 b are configured to be axially aligned with each otherwhen the die cavity 138 is in the closed position. That is, the firstmovable die block portion 116 a and the second movable die block portion116 b are axially aligned with each other, when the die cavity 138 is inthe closed position, such that a contact surface 139 of the firstmovable die block portion 116 a engaged with a contact surface 141 ofthe second movable die block portion 116 b. In one embodiment, thecontact surfaces 139 and 141 of the first movable die block portion 116a and the second movable die block portion 116 b are substantiallyplanar surfaces.

In one embodiment, the first die body 122 includes an opening 123 toreceive the first movable die block 116 a. In one embodiment, the seconddie body 130 includes an opening 131 to receive the second movable dieblock 116 b. In one embodiment, the openings 123 and 131 are axiallyaligned with each other when the die cavity 138 is in the closedposition. In one embodiment, the first movable die block portion 116 aand the second movable die block portion 116 b are shaped and configuredto slip fit into their corresponding openings 123 and 131, respectively.

In one embodiment, the forming system 110 includes a first gas cylinderspring 153 and a second gas cylinder spring 155. In one embodiment,elements of the first gas cylinder spring 153 and the second gascylinder spring 155 may generally resemble and function in a mannersimilar to corresponding elements of the gas cylinder spring 48. In oneembodiment, the first gas cylinder spring 153 is disposed in the firstdie assembly 112 and the second gas cylinder spring 155 is disposed inthe second die assembly 114. In one embodiment, both the first gascylinder spring 153 and the second gas cylinder spring 155 areoperatively associated with the cam driver member 146. In oneembodiment, the first gas cylinder spring 153 is larger than the secondgas cylinder spring 155 and is configured to apply a relatively largeforce on the cam driver member 146 than that of the second gas cylinderspring 155.

In one embodiment, the cam driver member 146 has a downwardly facingslanted cam surface 150 which is constructed and arranged to cooperateor engage with an upwardly facing slanted cam surface 152 of the secondmovable die block 116 b.

In one embodiment, the forming system 10 includes an anti-rotationmember 151 that is configured to prevent rotation of the second movabledie block portion 116 b. In one embodiment, the anti-rotation member 151is disposed in the second die body and is configured to move togetherwith the second movable die block portion 116 b while preventing thesecond movable die block portion 116 b from rotating with respect to thesecond die body 130. In one embodiment, the anti-rotation member 151 mayinclude one or restraining portions that are protruding toward thesecond movable die block portion 116 b for limiting the rotation of thesecond movable die block portion 116 b. In illustrative embodiment, theanti-rotation member 151 is disposed on a top surface of the secondmovable die block portion 116 b. In another embodiment, theanti-rotation member 151 may be disposed on a bottom surface or sidesurfaces of the second movable die block portion 116 b.

In one embodiment, the forming system 110 may include a screw and springarrangement 149 that is configured to both retain the movable die block116 in the desired position to apply the force (by the third diesurface) against the work piece 140. In one embodiment, the screw andspring arrangement 149 may be configured to retract the cam drivermember 146 and the second movable die block 116 b and, thus, the firstmovable die block(s) 116 a from its force applying position.

In the illustrative embodiment, one movable die block 116 is shown onthe right side of the forming system 110. However, it is contemplatedthat movable die block(s) may be positioned on the left side of theforming system 110. Also, the number of movable die blocks on each side(right side and left side) may vary. For example, in one embodiment, theforming system 110 may include a two movable die blocks per sideconfiguration or a three movable die blocks per side configuration.

In one embodiment, the opening 123 of the first die body 122 is athrough opening that enables the die surface 136 of the first movabledie block portion 116 a to contact or engage with the adjoining contactsurface of the work piece 140 and the contact surface 139 of the firstmovable die block portion 116 a to engage with the contact surface 141of the second movable die block portion 116 b. In one embodiment, theopening 131 of the second die body 130 is a through opening that enablesthe contact surface 139 of the first movable die block portion 116 a toengage with the contact surface 141 of the second movable die blockportion 116 b and the downwardly facing slanted cam surface 150 of thecam driver member 146 to cooperate or engage with the upwardly facingslanted cam surface 152 of the second movable die block 116 b.

The operation of the forming system 110 will now be described.

When the die cavity is the open position, the second nitrogen cylinderspring 155 applies pressure on the cam driver member 146 sliding itupwards towards its original position. That is, prior to the beginningof the next forming cycle, the second nitrogen cylinder spring 155 isenergized to move the cam driver member 146 to its original position.

The forming procedure begins with the configuration in which the heatedwork piece 140 is placed upon the lower die body 130, when the diecavity is the open position. After the work piece 140 is mounted on thelower die body 130, the upper die assembly 112 is lowered (to its dieposition) by the stamping press or ram until a downwardly facing, lowerclamping surface of the upper die assembly 112 engages an upwardlyfacing surface of the sheet metal blank 140 such that the work piece 140is sandwiched between the die surface 124 of the upper die body 122, thedie surface 136 of the movable die block 116 a and the die surface 132of the lower die body 130.

When the die cavity is in the closed position, the contact surface 139of the first movable die block portion 116 a is axially aligned with andengages the contact surface 141 of the second movable die block portion116 b. When the die cavity is in the closed position, the gas cylinderspring 153 operates to apply a force on the cam driver member 146. Inone embodiment, the gas cylinder spring 153 operates to apply thedownward force on a top surface 147 of the cam driver member 146. Theforce applied by the gas cylinder spring 153 on the top surface 147 ofthe cam driver member 146 causes the cam driver member 146 to move in adownwardly direction. In one embodiment, the movement of the cam drivermember 146 is a linear longitudinal downwardly movement. In oneembodiment, the movement of the cam driver member 146 is a verticalmovement. In one embodiment, the movement of the cam driver member 146is in a direction as shown by an arrow DF.

As the cam driver member 146 moves in the downwardly direction, thedownwardly facing slanted cam surface 150 of the cam driver member 146cams or wedges against the upwardly facing slanted cam surface 152 ofthe second movable die block portion 116 b causing the second movabledie block portion 116 b to move inwardly towards the center of theforming system 110. That is, as the cam driver member 146 moves in thedownwardly direction, the downwardly facing slanted cam surface 150 ofthe cam driver member 146 slidingly engages and bears against theupwardly facing slanted cam surface 152 of the second movable die blockportion 116 b thereby advancing the second movable die block portion 116b in a direction transverse to the axial downwardly direction of themovement of the cam driver member 146.

In one embodiment, the movement of the second movable die block portion116 b is a transverse or lateral movement (towards the center of theforming system 110). In another embodiment, the movement of the secondmovable die block portion 116 b is a linear transverse or lateralmovement (towards the center of the forming system 110). The inwardlymovement of the second movable die block portion 116 b in turn forcesthe first movable die block portion 116 a against the lower die body 130creating pressure against the work piece 140 received in the die cavity.That is, the transverse or lateral movement of the second movable dieblock portion 116 b exerts a (compressive) force on the first movabledie block portion 116 a to drive the first movable die block portion 116a in a direction transverse to the axis A′-A′. For example, as thesecond movable die block portion 116 b moves in the transverse orlateral direction, the contact surface 141 of the second movable dieblock portion 116 b engages with and applies a force on the contactsurface 139 of the first movable die block portion 116 a advancing thefirst movable die block portion 116 a in a direction transverse to theaxis A′-A′. The transverse movement of the first movable die blockportion 116 a exerts a force on the work piece received in the diecavity. In one embodiment, the movable die block 116 a is configured toapply pressure to the side walls of the work piece received in the diecavity (or the formed part). In one embodiment, the movement of thefirst movable die block portion 116 a and the second movable die blockportion 116 b are transverse movements in a direction transverse to theaxis A′-A′, while the movement of the cam driver member 146 is an axiallongitudinal, vertical movement in a direction parallel to or along withthe axis A′-A′.). In one embodiment, the movement of the first movabledie block portion 116 a and the second movable die block portion 116 bare in the direction of an arrow S.

Thus, the downward axial force from the cam driver member 146 istranslated into a sideward or laterally applied force on the work piece140 by the die block 116 a. The arrangement of the cam driver member 146and the movable die blocks 116 a and 116 b are configured to convert theaxial or longitudinal movement of the cam driver member 146 into alateral or transverse movement of translation (of the movable die blocks116 a and 116 b) so as to apply a transverse force on the work piece 140received in the die cavity. In one embodiment, the force may betranslated from downward (on the cam driver member 146) to sideways (ofthe die block 116 a on the side walls of the work piece 140) by about 90degree. In another embodiment, the force may be translated fromdownwards to sideways by about 30 to 150 degree. In another embodiment,the force may be translated from downwards to sideways by about 60 to120 degree.

The cam driver member 146 is configured to urge the die surface 136 ofthe first movable die block portion 116 a tightly against its adjoiningcontact surface of the work piece 140 so as to increase the area ofcontact between the first movable die block portion 116 a and the workpiece 140, and provide an improved heat transfer path between the workpiece 140 and the movable die block portion 116 a.

The camming action has effected displacement of the second movable dieblock portion 116 b and the first movable die block portion 116 a so asto impose maximum contact pressure between the work piece 140 and themovable die block portion 116 a. In one embodiment, increased forceapplied by the third die surface 136 against the work piece 140increases thermal transfer between the third die surface 136 and thework piece 140. The movable die blocks 116 apply pressure to the sidewalls of the formed part. This provides sufficient contact pressure toachieve an acceptable heat transfer coefficient in turn allowing theentire part to transform into Martensite.

In the illustrative embodiment of FIG. 1, the gas cylinder springapplies a transverse force on the cam driver member to effectdisplacement of the movable die block 16, while in the embodiments ofFIGS. 2 and 3, the gas cylinder spring applies a longitudinal force onthe cam driver member to effect displacement of the second movable dieblock portion 116 b and the first movable die block portion 116 a.However, in both these embodiments, the movable die block applies aforce to the work piece that is predominantly transverse to forcesapplied to the work piece by the first die assembly and the second dieassembly.

FIGS. 4 and 5 are schematic diagrams of a hot stamping/forming system410 in accordance with another embodiment of the present patentapplication. The hot stamping/forming 410 includes a first die assembly412 having a first die surface 424, a second die assembly 414 having asecond die surface 432, and a movable die block 416 having a third diesurface 436. The first die surface 424, the second die surface 432 andthe third die surface 436 are configured to cooperate to form a diecavity 438 therebetween so as to receive a work piece 440 therein.Relative movement between the first die assembly 412 and the second dieassembly 414 along a first axis A″-A″ moves the die cavity 438 betweenan open position and a closed position. The die block 416 is movablerelative to the first die assembly 412 in a direction transverse to thefirst axis A″-A″, and the die block applies a force SF″ on the workpiece 440 that is predominantly transverse to forces F′ applied to thework piece 440 by the first die assembly 412 and the second die assembly414.

The system 410 also includes a cooling system 418 operatively associatedwith the first die assembly 412, the second die assembly 414 and themovable die block 416. In one embodiment, elements of the cooling system418 may generally resemble and function in a manner similar tocorresponding elements of the cooling system 18. Although notillustrated, the first die assembly 412, the second die assembly 414 andthe movable die block 416 each include cooling structures or channelsassociated therewith so that the first die surface, the second diesurface and the third die surface cool the work piece 440 in contacttherewith when the die cavity 438 is closed.

This embodiment is similar to the embodiments previously described,except for the differences as will be noted below.

In one embodiment, the first die body 422 includes an opening 423 toreceive the movable die block 416 and the cam driver member 446. In oneembodiment, the opening 423 has a L-shaped configuration.

In one embodiment, the forming system 410 includes a gas cylinder spring448 that is configured to apply an upwardly force on the cam drivermember 446 when the die cavity is in the closed position. In oneembodiment, elements of the gas cylinder spring 448 may generallyresemble and function in a manner similar to corresponding elements ofthe gas cylinder spring 48.

In one embodiment, the cam driver member 446 has an upwardly downwardlyfacing slanted cam surface 450 which is constructed and arranged tocooperate or engage with a downwardly facing slanted cam surface 452 ofthe movable die block 416.

In one embodiment, the forming system 410 may include a screw and springarrangement 449 that is configured to both retain the movable die block416 in the desired position to apply the force (by the third diesurface) against the work piece 440. In one embodiment, the screw andspring arrangement 449 may be configured to retract the cam drivermember 446 and, thus, the movable die block 416 from its force applyingposition.

In the illustrative embodiment, one movable die block 416 is shown oneach side (the right side and the left side) of the forming system 410.However, the number of movable die blocks on each side may vary. Forexample, in one embodiment, the forming system 410 may include a twomovable die blocks per side configuration or a three movable die blocksper side configuration.

In one embodiment, the opening 423 of the first die body 422 is athrough opening that enables the die surface 436 of the movable dieblock 416 to contact or engage with the adjoining contact surface of thework piece 440.

The operation of the forming system 410 will now be described.

The forming procedure begins with the configuration in which the heatedwork piece 440 is placed upon the lower die body 430, when the diecavity is the open position. After the work piece 440 is mounted on thelower die body 430, the upper die assembly 412 is lowered (to its dieposition) by the stamping press or ram until a downwardly facing, lowerclamping surface of the upper die assembly 412 engages an upwardlyfacing surface of the sheet metal blank 440 such that the work piece 440is sandwiched between the die surface 424 of the upper die body 422, thedie surface 436 of the movable die block 416 and the die surface 432 ofthe lower die body 430.

When the die cavity is in the closed position, as shown in FIG. 5, thegas cylinder spring 448 operates to apply a force on the cam drivermember 446. In one embodiment, the gas cylinder spring 448 operates toapply the upwardly force on a bottom surface 447 of the cam drivermember 446. The force applied by the gas cylinder spring 448 on thebottom surface 447 of the cam driver member 446 causes the cam drivermember 446 to move in an upwardly direction. In one embodiment, themovement of the cam driver member 446 is in a linear longitudinalupwardly movement.

As the cam driver member 446 moves in the upwardly direction, theupwardly facing slanted cam surface 450 of the cam driver member 446cams or wedges against the downwardly facing slanted cam surface 452 ofthe movable die block 416 causing the movable die block 416 to moveinwardly towards the center of the forming system 410. That is, theupwardly movement of the cam driver member 446 forces the movable dieblock 416 against the lower die body 430 creating pressure against thework piece 440. In one embodiment, the movement of the movable die block416 is a linear transverse movement (towards the center of the formingsystem 110).

The cam driver member 446 is configured to urge the die surface 436 ofthe movable die block 416 tightly against its adjoining contact surfaceof the work piece 440 so as to increase the area of contact between themovable die block 416 and the work piece 440, and provide an improvedheat transfer path between the work piece 440 and the movable die block416. The camming action has effected displacement of the movable dieblock portion 416 so as to impose maximum contact pressure between thework piece 440 and the movable die block 416. In one embodiment,increased force applied by the third die surface 436 against the workpiece 440 increases thermal transfer between the third die surface 436and the work piece 440. The movable die blocks 416 apply pressure to theside walls of the formed part. This provides sufficient contact pressureto achieve an acceptable heat transfer coefficient in turn allowing theentire part to transform into Martensite.

In one embodiment, the hot formed member is a vehicle body member orvehicle body assembly. In one embodiment, the vehicle body componentthat is formed or produced by the system of the present application mayinclude external body panel members, vehicle body pillars (e.g.,A-pillars, B-pillars, etc.), vehicle side impact protection members,vehicle sill members, vehicle frame components, vehicle bumper beams,vehicle bumper mounts, vehicle door pillar reinforcement members,vehicle roof frame members, vehicle roof panel members, vehicle roofrails, vehicle rear end cross members, vehicle rocker members, vehicledoor intrusion beams and vehicle front end cross members.

In one embodiment, the forming system may include a blank or work pieceholder, which is mechanism configured to prevent the blank or work piecefrom moving during the forming procedure and/or quenching procedure. Inanother embodiment, the blank or work piece holder may be optional.

In one embodiment, the forming system may include a pair of ejectionstructures (not shown), which are disposed within the lower die body.The ejection structures may be configured to eject the hot formedcomponent (i.e., in the event it is form fitted to the die surfaces ofthe lower die assembly) after the forming procedure. In anotherembodiment, the ejection structures may be optional.

In one embodiment, the hot formed component may be held inside theforming system during the cooling or quenching procedure so as tomaintain the desired shape of the hot formed component while it is beingcooled and/or hardened. In one embodiment, a fixture may be used tomaintain the dimensions of the hot formed component during the coolingprocedure. In another embodiment, the fixture may be optional.

Construction of the forming system in accordance with the teachings ofthe present application permits the rate of quenching at each point onthe die surface to be controlled in a precise manner. This isparticularly advantageous for high-volume production as it is possibleto employ relatively short overall cycle times while achieving anAustenite-to-Martensite transformation.

In one embodiment, the hot formed member may be referred to as a hotstamped member or a hot shaped member. For example, the hot stampingallows for the forming of complex part geometries with the final productachieving ultra high strength material properties.

Although the present patent application has been described in detail forthe purpose of illustration, it is to be understood that such detail issolely for that purpose and that the present patent application is notlimited to the disclosed embodiments, but, on the contrary, is intendedto cover modifications and equivalent arrangements that are within thespirit and scope of the appended claims. In addition, it is to beunderstood that the present patent application contemplates that, to theextent possible, one or more features of any embodiment can be combinedwith one or more features of any other embodiment.

What is claimed is:
 1. A forming system comprising: a first die assemblyhaving a first die surface; a second die assembly having a second diesurface; a movable die block having a third die surface; and a coolingsystem operatively associated with the first die assembly, the seconddie assembly and the movable die block, wherein the first die surface,the second die surface and the third die surface are configured tocooperate to form a die cavity therebetween so as to receive a workpiece therein, wherein relative movement between the first die assemblyand the second die assembly along a first axis moves the die cavitybetween an open position and a closed position, wherein the die block ismovable relative to the first die assembly in a direction transverse tothe first axis, and wherein the die block applies a force to the workpiece that is predominantly transverse to forces applied to the workpiece by the first die assembly and the second die assembly.
 2. Theforming system of claim 1, wherein the die block applies the force tothe work piece that is perpendicular to the forces applied to the workpiece by the first die assembly and the second die assembly.
 3. Theforming system of claim 1, wherein, in the closed position, the firstand second die surfaces apply the forces to the work piece in adirection generally corresponding to the first axis.
 4. The formingsystem of claim 1, wherein increased force applied by the third diesurface against the work piece increases thermal transfer between thethird die surface and the work piece.
 5. The forming system of claim 1,wherein the first die assembly, the second die assembly and the movabledie block having a cooling structure associated therewith so that thefirst die surface, the second die surface and the third die surface coolthe work piece in contact therewith when the die cavity is closed. 6.The forming system of claim 1, further comprising a biasing device thatis configured to enable the movement of the die block relative to thefirst die assembly.
 7. The forming system of claim 6, wherein thebiasing device is a gas cylinder spring.
 8. The forming system of claim7, wherein the gas cylinder spring is a nitrogen cylinder spring.
 9. Theforming system of claim 6, further comprising a cam driver member thatis configured to be operatively connected to the biasing device, whereinthe biasing device and the cam driver member are configured to enablethe movement of the die block relative to the first die assembly. 10.The forming system of claim 9, wherein the cam driver member and themovable die block have cam surfaces that are configured to engage witheach other to enable the movement of the die block relative to the firstdie assembly.
 11. The forming system of claim 10, wherein the cam drivermember and the movable die block are configured to translate a downwardaxial force of the cam driver member into a lateral or side appliedforce on the work piece by the movable die block.
 12. The forming systemof claim 10, wherein the cam driver member and the movable die block areconfigured to translate a downward axial force of the movable die blockinto a lateral or side applied force on the work piece by the movabledie block.
 13. The forming system of claim 11, wherein the force istranslated from the downward axial force to the lateral or side appliedforce by 90 degrees.
 14. The forming system of claim 1, wherein the diecavity is configured to have a shape that corresponds to a final shapeof the work piece after a hot forming procedure.
 15. The forming systemof claim 1, wherein the cooling system includes cooling channels formedin the die block, wherein the cooling channels are constructed andarranged to carry a cooling fluid.
 16. The forming system of claim 15,wherein the cooling system includes a pressure source for forcing thecooling fluid through the cooling channels.
 17. The forming system ofclaim 1, wherein the first die assembly is an upper die assembly.
 18. Amethod of forming a sheet metal member in a forming system comprising afirst die assembly having a first die surface, a second die assemblyhaving a second die surface, a movable die block having a third diesurface, and a cooling system operatively associated with the first dieassembly, the second die assembly and the movable die block, wherein thefirst die surface, the second die surface and the third die surface areconfigured to cooperate to form a die cavity therebetween so as toreceive a work piece therein, the method comprising: moving the firstdie assembly relative to the second die assembly along a first axis tomove the die cavity from an open position to a closed position, movingthe die block relative to the first die assembly in a directiontransverse to the first axis, and applying a force to the work piecewith the die block that is predominantly transverse to forces applied tothe work piece by the first die assembly and the second die assembly.19. The method of claim 18, wherein the force applied to the work pieceby the die block is perpendicular to the forces applied to the workpiece by the first die assembly and the second die assembly.
 20. Themethod of claim 18, wherein the forces applied to the work piece by thefirst die assembly and the second die assembly are in a directiongenerally corresponding to the first axis.
 21. The method of claim 18,wherein increased force applied by the third die surface against thework piece increases thermal transfer between the third die surface andthe work piece.
 22. The method of claim 18, wherein the first diesurface, the second die surface and the third die surface are configuredto cool the work piece in contact therewith when the die cavity isclosed.
 23. The method of claim 18, wherein the first die assembly is anupper die assembly.